Panel and method of manufacture

Abstract

A panel, in particular a floor panel, has a core of a wooden material, in particular MDF or HDF, or a wooden material/plastic mixture. A pattern is arranged on a visible side. The visible side is provided on at least one side edge (I, II) with a chamfer running at an angle α hereto and a length (L). The angle α of at least one of the chamfers varies over the length (L).

Claims

1. A method for producing a panel with a core of a wooden material, comprising guiding a side edge (I or II) of the panel past an oscillating laser which has a mass unbalance to generate an oscillation about an axis running parallel to a transport direction (T) of the panel to form a chamfer having an angle which at different points along a length of the panel have different values, wherein the angle at the different points forms angles α, α.sub.1, α.sub.2 which are arbitrary and non-continuous and changes over a length (L.sub.1) of an area of the chamfer, wherein the angle is determined iteratively in an area embodied at a constant angle in order to obtain a V joint of different widths due to the changing angles α, α.sub.1, α.sub.2 over the length of the panel, and a lower edge of the chamfer is cut straight, based on the visible side, such that an impermeable connection of two panels is provided.

2. The method according to claim 1, wherein a pattern is directly printed on the top of the panel.

3. The method according to claim 1, wherein a pattern is applied to a paper web which together with a synthetic resin layer is pressed to a visible side of the panel.

4. The method according to claim 1, wherein a pattern is printed out directly onto the chamfer.

5. The method according to claim 4, wherein a relief is embossed in a surface of the chamfer.

6. The method according to claim 5, wherein onto the pattern on the chamfer a synthetic resin layer is applied and the relief is embossed in the synthetic resin layer.

7. The method according to claim 4, wherein the pattern is printed directly onto at least one of the visible side and the chamfer.

8. The method according to claim 4, further comprising embossing a relief in a surface of the chamfer which corresponds to a structure of the pattern.

9. The method according to claim 8, wherein the structure is a wood grain.

10. The method according to claim 1, wherein a chamfer is formed at two opposite side edges (I, II) of the panel.

11. The method according to claim 10, wherein the chamfer is formed at all side edges of the panel.

12. The method according to claim 1, wherein a size of an angle of the chamfer varies arbitrarily over the length (L) of the chamfer.

13. The method according to claim 12, wherein the angle at a point along the panel varies in a range of 15°-89°.

14. The method according to claim 13, wherein the angle at a point along the panel varies between 37°and 42°.

15. The method according to claim 1, wherein the chamfer is flat or curved in a convex or concave manner.

16. The method according to claim 1, wherein the wooden material is MDF or HDF or a wooden material/plastic mixture.

17. A method for producing a panel, comprising guiding a side edge (I or II) of the panel past an oscillating laser tool which has a mass unbalance to generate an oscillation about an axis running parallel to a transport direction (T) of the panel to form a chamfer having an angle which at different points along a length of the panel have different values and at its lower edge of the chamfer runs straight, based on a visible side, such that an impermeable connection of two panels is provided.

18. The method according to claim 17, wherein the angle is in a range of 15°-89°.

19. The method according to claim 18, wherein a relief is embossed in a surface of the chamfer.

20. The method according to claim 19, wherein a pattern is printed directly on a visible side of a core of the panel and the chamfer such that the visible side is devoid of a decorative paper or carrier layer.

21. The method according to claim 20, wherein a synthetic resin layer is applied on the chamfer.

22. The method according to claim 21, wherein a relief is embossed in the synthetic resin layer surface of the chamfer which corresponds to the pattern printed directly onto the visible side and the chamfer.

23. The method according to claim 17, wherein the laser tool oscillates about an axis running parallel to a transport direction (T) of the panel.

24. The method according to claim 17, wherein the laser tool is a laser.

25. A method for producing a panel with a core of a wooden material, comprising guiding a side edge (I or II) of the panel past an oscillating laser which has a mass unbalance to generate an oscillation about an axis running parallel to a transport direction (T) of the panel to form a chamfer having an angle which at different points along a length of the panel have different values, wherein a size of an angle of the chamfer varies arbitrarily over the length (L) of the chamfer in a range of 15°-89°, wherein the angle at the different points forms angles α, α.sub.1, α.sub.2 which are arbitrary and non-continuous and changes over a length (L.sub.1) of an area of the chamfer, wherein the angle is determined iteratively in an area embodied at a constant angle in order to obtain a V joint of different widths due to the changing angles α, α.sub.1, α.sub.2 over the length of the panel and a lower edge of the chamfer is cut straight, based on a visible side, such that an impermeable connection of two panels is provided.

26. A method for producing a panel with a core of a wooden material, comprising guiding a side edge (I or II) of the panel past an oscillating laser which oscillates about an axis running parallel to a transport direction (T) of the panel to form a chamfer having an angle which at different points along a length of the panel have different values, wherein: a size of an angle of the chamfer varies arbitrarily over the length (L) of the chamfer in a range of 15°-89° and at a lower edge of the chamfer remains constant based on a visible side, such that an impermeable connection of two panels is provided; a pattern is printed out directly onto the chamfer; a relief is embossed in a surface of the chamfer; and onto the pattern on the chamfer a synthetic resin layer is applied and the relief is embossed in the synthetic resin layer, wherein to increase precision during machining, the panel is guided through and between two plates and guided past the oscillating laser.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:

(2) FIG. 1 shows a side view of three panels connected to one another in partial representation;

(3) FIG. 2 shows a plan view of the panels according to FIG. 1;

(4) FIG. 3 shows a representation of FIG. 2 with different angles indicated;

(5) FIG. 4 shows an exemplary embodiment of a panel in side view;

(6) FIG. 5 shows a schematic representation of the chamfer on a panel in perspective representation; and

(7) FIG. 6 shows a simplified sketch of a production step.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

(8) The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.

(9) Referring to FIGS. 1-6 and more specifically FIG. 4, the core 3 of the panel 1 comprises a wooden material, in particular MDF or HDF, a wooden material/plastic mixture or a pure plastic mixture. The visible side of the panel 1 is provided with a pattern 2. On the opposite side edges I, II, the panel 1 has a tongue 4 or a groove 5 corresponding thereto. The tongue 4 and groove 5 are provided with locking means 6, 7, via which two panels 1, 1a connected to one another can be locked to one another so that they can be laid without glue. Such panels are called click-in panels.

(10) On the opposite side edges I, II, the panel 1 is provided with a chamfer 8, 9 that is embodied over the length L of the panel 1 at different angles α, α.sub.1, α.sub.i of less than 1° to 75°, e.g., see FIG. 3. The size of the angles α, α.sub.1, α.sub.2 does not change continuously, but arbitrarily, whereby the size of the angles α, α.sub.1, α.sub.2 changes over the length L.sub.1 of the area of the chamfer 8, 9, which is determined iteratively in an area embodied at a constant angle α.sub.1, in order to obtain a V joint that is “worn” in the most natural looking manner possible. To this end, for example, the joint of a floor of genuine wood panels having the corresponding appearance of wear can be measured and the angles and lengths transferred accordingly.

(11) As FIG. 2 shows, the width B of the chamfers 8, 9 or the width of the V joint 19 differs due to the changing angle α, α.sub.1, α.sub.2 over the length L of the panel 1, 1a, 1b. The chamfers 8, 9 can be embodied to be flat or curved in a convex or concave manner. The angles α, α.sub.1, α.sub.2 vary in the range of 15°-89°. Visually attractive joints can be produced with angles a between 37° and 42° of the chamfers 8, 9.

(12) Referring again to FIG. 4, the lower edge 10, 11 of the chamfers 8, 9 runs straight, based on the visible side, to ensure that an impermeable connection of two panels 1a, 1b, 1c is guaranteed and no moisture can penetrate via the vertical joint. The chamfers 8, 9 are varnished or coated with a melamine resin. The pattern of the chamfer 8, 9 is adapted to the pattern 2 on the visible side.

(13) A variety of chamfer geometries can be produced by means of a laser cutting head 13 attached to a CNC support 12. In such an embodiment, the cutting head is connected with a light guide to the beam source.

(14) As FIG. 6 shows, the panel 1 to be machined is guided in a so-called double-end profiler 15 and transported in the transport direction T. The top and/or bottom of panel 1 comes into contact with a chain-like conveyor device (not shown in detail) which conveys the panel 1 along its direction of movement T. The panel 1 passes through different machining stations.

(15) In the machining stations, the side edges of the panel 1 projecting out of the conveyor 15 are predominantly machined. For example, the tongue 4 and the groove 6 are milled.

(16) In order to increase the precision during machining, the panel 1 is guided through between two metal plates 16, 17 and fixed by pressure shoes. Finally, the panel 1 is guided past the laser 13, which oscillates about the axis 14 running parallel to the transport direction T in the direction S. The CNC support 12 oscillates up and down depending on the laser oscillation S so that the lower edge 10, 11 of the chamfers 8, 9 remains constant. The frequency of the oscillation of the laser 13 is non-uniform but reproducible. The angle α is generated on the panel 1 depending on the angle of the laser 13 to the axis 14. The laser beam 18 vaporizes the material it hits and penetrates the panel 1. The residual beam hits a special beam trap and is destroyed there.

(17) Naturally, conventional chip-removing machining tools (e.g., mills, planes) can be used instead of the laser 13. To produce the oscillating movement of the machining tool, it can also be provided with a mass unbalance.

(18) It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.